Hydrogen generator

ABSTRACT

A hydrogen generator including a series of plates positioned in an electrolysis chamber. The plates are configured to generate hydrogen. The chamber has a water inlet configured to receive water from a water source and a hydrogen outlet configured to allow the hydrogen to exit therefrom. The plates include a positive plate, a negative plate, and a neutral plate. Each of the plates has through-holes configured to allow the water and the hydrogen to flow therethrough. The positive and negative plates are configured to be connected to positive and negative terminals, respectively, of an electrical power source. The water inside the chamber forms an electrical connection between the positive and negative plates that splits the water into the hydrogen and oxygen.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention is directed generally to devices configured togenerate hydrogen gas and, more particularly, to devices that generatehydrogen gas by performing electrolysis on water.

Description of the Related Art

Hydrogen is considered a clean energy source. Unfortunately, manycurrent methods of generating hydrogen for use as a fuel source have notbeen cost effective. Further, many current methods of generatinghydrogen are not capable of generating a sufficient amount of hydrogenat a desired rate.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a block diagram of a system that includes a hydrogengenerator.

FIG. 2 is an illustration of water being split by electrolysis intohydrogen and oxygen.

FIG. 3 is a perspective view of a first embodiment of the hydrogengenerator connected to both a water source and a power controller.

FIG. 4A is a first partially exploded perspective view of the hydrogengenerator of FIG. 3.

FIG. 4B is a second partially exploded perspective view of the hydrogengenerator of FIG. 3.

FIG. 5 is an enlarged side view of an upper portion of the hydrogengenerator of FIG. 3 omitting its ties and first and second end caps.

FIG. 6 is a view of a first side of a plate of the hydrogen generator ofFIG. 3.

FIG. 7 is a view of a first side of a first embodiment of a positiveplate of the hydrogen generator of FIG. 3.

FIG. 8 is a view of a second side of a first embodiment of a negativeplate of the hydrogen generator of FIG. 3.

FIG. 9 is a view of a first side of a first embodiment of a firstneutral plate of the hydrogen generator of FIG. 3.

FIG. 10 is a view of a second side of a first embodiment of a secondneutral plate of the hydrogen generator of FIG. 3.

FIG. 11 is a back view of a seal of the hydrogen generator of FIG. 3.

FIG. 12 is a view of a first side of a second embodiment of the positiveplate of the hydrogen generator of FIG. 3.

FIG. 13 is a view of a second side of a second embodiment of thenegative plate of the hydrogen generator of FIG. 3.

FIG. 14 is a view of a first side of a second embodiment of the firstneutral plate of the hydrogen generator of FIG. 3.

FIG. 15 is a view of a second side of a second embodiment of the secondneutral plate of the hydrogen generator of FIG. 3.

FIG. 16 is a perspective view of a second embodiment of the hydrogengenerator configured to low-density applications.

FIG. 17 is a view of a first side of a positive plate of the hydrogengenerator of FIG. 16.

FIG. 18 is a view of a second side of a negative plate of the hydrogengenerator of FIG. 16.

FIG. 19 is a view of a first side of a first neutral plate of thehydrogen generator of FIG. 16.

FIG. 20 is a view of a second side of a second neutral plate of thehydrogen generator of FIG. 16.

FIG. 21 is a front view of a seal of the hydrogen generator of FIG. 16.

FIG. 22 is a front view of a membrane of the hydrogen generator of FIG.16.

FIG. 23 is a top view of a slice taken through the hydrogen generator ofFIG. 16.

FIG. 24 is a top view of the slice of FIG. 23 illustrated with its firstgas chamber shaded.

FIG. 25 is a circuit diagram of the power controller configured for usewith the hydrogen generators of FIGS. 3 and 16.

Like reference numerals have been used in the figures to identify likecomponents.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a block diagram of a system 100 that includes a hydrogengenerator 106. The hydrogen generator 106 is connected to an electricalpower controller 108 by electrical conductors 110 (e.g., wires). Thepower controller 108 may be configured to deliver direct current (“DC”)to the hydrogen generator 106. As shown in FIG. 3, the power controller108 has a positive terminal T+ and a negative terminal T−. The powercontroller 108 is configured to determine a voltage of the currentdelivered to the hydrogen generator 106. Thus, the power controller 108is configured to deliver current having an adjustable voltage. The powercontroller 108 is connected to or includes a power source 109 that maybe implemented as a battery or a power converter configured to receivealternating current (“AC”) from an AC source (e.g., a conventional wallsocket) and convert the AC to DC.

The hydrogen generator 106 is connected to a water source 112 (e.g., awater tank) by one or more water lines 114. The hydrogen generator 106is configured to receive water 116 from the water source 112. Referringto FIG. 2, the hydrogen generator 106 uses electrolysis to split watermolecules (H₂O) 117 (in the water 116) into hydrogen (H) atoms 118 andoxygen (O) atoms 119. Next, two of the hydrogen atoms 118 combine toform hydrogen gas (H₂) 120, and two of the oxygen (O) atoms 119 combineto form oxygen gas (O₂) 121.

Referring to FIG. 1, the water 116 may include a catalyst 122, such aspotassium hydroxide (KOH). By way of a non-limiting example, the watersource 112 may be configured to hold about 5 liters of water. About 600grams of the catalyst 122 (e.g., KOH) may be added to the 5 liters ofwater. In other words, about 120 grams of the catalyst 122 may be addedper liter of water.

The hydrogen gas 120 (see FIG. 2) produced by the hydrogen generator 106may be conducted (e.g., by one or more hydrogen gas lines 128) to ahydrogen reservoir 130. In some embodiments, the water source 112 mayalso function as the hydrogen reservoir 130. The hydrogen gas 120 (seeFIG. 2) may be conducted (e.g., by one or more gas lines 136) from thehydrogen reservoir 130 to an optional gas control system 132 that isconfigured to transfer the hydrogen gas 120 to a hydrogen consumingprocess and/or device 134. If the optional gas control system 132 hasbeen omitted, the gas line(s) 136 may conduct the hydrogen gas 120 (seeFIG. 2) directly to the hydrogen consuming process and/or device 134.Alternatively, the hydrogen gas 120 (see FIG. 2) may remain in thehydrogen reservoir 130 for later use.

The oxygen gas 121 (see FIG. 2) produced by the hydrogen generator 106may be conducted (e.g., by the hydrogen gas line(s) 128 and/or one ormore oxygen gas lines 124) to an oxygen reservoir 126. In someembodiments, the hydrogen reservoir 130 and/or the water source 112 mayfunction as the oxygen reservoir 126. The oxygen gas 121 (see FIG. 2)may be conducted (e.g., by one or more oxygen gas lines 138) from theoxygen reservoir 126 to the optional gas control system 132 or thehydrogen consuming process and/or device 134. Alternatively, the oxygengas 121 (see FIG. 2) may be vented into the surrounding environmentinstead of being conducted to the oxygen reservoir 126. By way of yetanother non-limiting example, the oxygen gas 121 (see FIG. 2) may remainin the oxygen reservoir 126 for later use.

The hydrogen generator 106 includes one or more cells 140. In theexample illustrated, the hydrogen generator 106 includes cells 140A and140B, which are substantially identical to one another. However, thehydrogen generator 106 may include any number of cells each like thecells 140A and 140B. For example, FIG. 3 illustrates an implementationin which the hydrogen generator 106 includes only the cell 140A. Whenthe hydrogen generator 106 includes more than one cell, such as thecells 140A and 140B, the electrical conductors 110 may connect the powercontroller 108 to the cells in series. The water source 112 may beconnected to the cells in parallel.

In the embodiment illustrated in FIG. 3, the water source 112 functionsas both the hydrogen reservoir 130 and the oxygen reservoir 126. Thus,the hydrogen gas line(s) 128 connect the hydrogen generator 106 to thewater source 112 and conduct both the hydrogen gas 120 (see FIG. 2) andthe oxygen gas 121 (see FIG. 2) into the water source 112. Then, the gasline(s) 136 conduct both the hydrogen gas 120 (see FIG. 2) and theoxygen gas 121 (see FIG. 2) from the water source 112 to the optionalgas control system 132 (see FIG. 1) or the hydrogen consuming processand/or device 134 (see FIG. 1). In the embodiment illustrated in FIG. 3,the cell 140A includes a plurality of plates 142, a plurality of seals144 (see FIGS. 4A, 5, and 11), a first end cap 146, a second end cap148, a plurality of ties 152, and an optional plurality of fasteners 154(e.g., nuts).

Referring to FIG. 6, each of the plates 142 has a generally rectangularouter shape 158 surrounding a body portion 160. The generallyrectangular outer shape 158 has a length L1 (e.g., about 10 cm) and aheight H1 (e.g., about 15 cm). The generally rectangular outer shape 158has four corners C1-C4 and four edges E1-E4. The corners C2-C4 are eachnotched or cutout to define cutouts 161B-161D. The cutouts 161B-161D mayeach have a quarter-circle shape centered at the corners C2-C4,respectively. By way of a non-limiting example, when the cutouts161B-161D have a quarter-circle shape, they may each have a radius ofabout 1.0 cm. In the embodiment illustrated, each of the plates 142 isgenerally planar.

In the embodiment illustrated, the edges E1 and E3 are shorter than thesides E2 and E4. The edges E1-E4 each have cutouts formed therein. Theshorter edges E1 and E3 each have two cutouts 162A and 162B, and thelonger edges E2 and E4 each have three cutouts 163A-163C. Each of thecutouts 162A-163C may have a semicircular shape centered on the edge inwhich the cutout is formed. By way of a non-limiting example, each ofthe cutouts 162A-163C may have a radius of about 0.5 cm.

The following are exemplary minimum distances defining positions of thecutouts 162A and 162B formed in each of the edges E1 and E3. A minimumdistance between the cutout 162A and the cutout 162B may be about 3 cm.A minimum distance between the cutout 162A formed in the edge E1 and thecorner C2 may be about 2.5 cm. Similarly, a minimum distance between thecutout 162A formed in the edge E3 and the corner C3 may be about 2.5 cm.A minimum distance between the cutout 162B formed in the edge E1 and thecorner C1 may be about 2.5 cm. Similarly, a minimum distance between thecutout 162B formed in the edge E3 and the corner C4 may be about 2.5 cm.

The following are exemplary minimum distances defining positions of thecutouts 163A-163C formed in each of the edges E2 and E4. A minimumdistance between the cutout 163A and the cutout 163B may be about 3 cm.A minimum distance between the cutout 163B and the cutout 163C may beabout 3.2 cm. A minimum distance between the cutout 163A formed in theedge E2 and the corner C2 may be about 3 cm. Similarly, a minimumdistance between the cutout 163A formed in the edge E4 and the corner C1may be about 3 cm. A minimum distance between the cutout 163C formed inthe edge E2 and the corner C3 may be about 2.8 cm. Similarly, a minimumdistance between the cutout 163C formed in the edge E4 and the corner C4may be about 2.8 cm.

The body portion 160 includes a plurality of through-holes 170. A firstembodiment of the plates 142 is illustrated in FIGS. 3-10. Referring toFIG. 6, in the first embodiments, the through-holes 170 include fivethrough-holes 171-175. By way of a non-limiting example, each of thethrough-holes 171-175 may have a circular shape with a radius of about0.5 cm. The through-holes 171-174 are arranged linearly in a series thatis substantially parallel with the edges E1 and E3. The through-holes171-174 are positioned nearer the edge E3 than the edge E1. Thethrough-holes 171 and 172 are spaced apart by a minimum distance ofabout 0.8 cm. The through-holes 172 and 173 are spaced apart by aminimum distance of about 0.8 cm. The through-holes 173 and 174 arespaced apart by a minimum distance of about 0.8 cm. The through-holes171-174 are spaced apart by a minimum distance of about 1.6 cm from theedge E3. The through-hole 171 is spaced apart by a minimum distance ofabout 2.0 cm from the edge E2. The through-hole 174 is spaced apart by aminimum distance of about 1.6 cm from the edge E4. The through-hole 175is positioned nearer the edge E1 than the edge E3. In the embodimentillustrated, the through-hole 175 is spaced apart by a minimum distanceof about 2.2 cm from each of the edges E1 and E4.

The body portion 160 may have an optional through-hole 178 positionedcloser to the corner C1 than the through-hole 175. By way of anon-limiting example, the through-hole 178 may have a circular shapewith a radius of about 0.2 cm. The through-hole 178 may be spaced apartby a minimum distance of about 0.3 cm from each of the edges E1 and E4.

While exemplary dimensions are provided above, through application ofordinary skill in the art to the present teachings, the plates 142 maybe sized or scaled appropriately for a desired application. For example,smaller plates may be used if less hydrogen is desired. Similarly,larger plates or multiple cells may be used if more hydrogen is desired.Each of the plates 142 is constructed from a substantially electricallyconductive material. By way of a non-limiting example, each of theplates 142 may be constructed from stainless steel and the like.

Referring to FIG. 5, the plates 142 are substantially parallel with oneanother and arranged in a series. The plates 142 include one or morepositive plates 101 (see FIG. 7), one or more negative plates 102 (seeFIG. 8), and one or more neutral plates positioned in between eachadjacent pair of positive and negative plates. For example, the neutralplate(s) may include a first neutral plate 103 (see FIG. 9) and a secondneutral plate 104 (see FIG. 10), which may alternate inside the cell140A (see FIGS. 1 and 3-4B). Referring to FIG. 7, the oxygen atoms 119(see FIG. 2) collect along each of the positive plate(s) 101 and a firstside 180 or a second side 182 (see FIGS. 5, 8, 10, 13, 15, 18, and 20)of any of the first and second neutral plates 103 (see FIG. 9) and 104(see FIG. 10) facing the positive plate 101. Referring to FIG. 8, thehydrogen atoms 118 (see FIG. 2) collect along each of the negativeplate(s) 102 and the first side 180 (see FIGS. 5-7, 9, 12, 14, 17, and19) or the second side 182 of any of the first and second neutral plates103 (see FIG. 9) and 104 (see FIG. 10) facing the negative plate 102.

Referring to FIG. 5, in the embodiment illustrated, the plates 142include two positive plates 142-PA and 142-PB (each like the positiveplate 101 illustrated in FIG. 7), two negative plates 142-NA and 142-NB(each like the negative plate 102 illustrated in FIG. 8), six firstneutral plates 142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 (eachlike the first neutral plate 103 illustrated in FIG. 9), and six secondneutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12(each like the second neutral plate 104 illustrated in FIG. 10). Insidethe cell 140A (see FIGS. 1 and 3-4B), the plates 142 may be arranged inthe following predetermined order from the first end cap 146 (see FIGS.3-4B, 16, 23, and 24) to the second end cap 148 (see FIGS. 3-4B, 16, 23,and 24): positive plate 142-PA, first neutral plate 142-N1, secondneutral plate 142-N2, first neutral plate 142-N3, second neutral plate142-N4, negative plate 142-NA, first neutral plate 142-N5, secondneutral plate 142-N6, first neutral plate 142-N7, second neutral plate142-N8, positive plate 142-PB, first neutral plate 142-N9, secondneutral plate 142-N10, first neutral plate 142-N11, second neutral plate142-N12, and negative plate 142-NB.

A pattern may be formed (e.g., etched, scratched, laser cut, embossed,printed, etc.) on the first and/or second sides 180 and 182 of each ofthe plates 142. The patterns may be configured to help direct water flowand/or gas flow through the cell 140A (see FIGS. 1 and 3-4B). Thepatterns may be configured to generate a desired volume of hydrogen gasat a desired rate. The patterns may help induce a desired current flowin the water 116 (see FIGS. 1-3). The patterns may help direct thehydrogen and oxygen gases 120 and 121 (see FIG. 2) through thethrough-holes 171-175 (see FIGS. 6-10) and toward the second end cap 148(see FIGS. 3-4B, 16, 23, and 24).

As mentioned above, each of the positive plates 142-PA and 142-PB (seeFIGS. 4A and 5) may be implemented as the positive plate 101 (see FIG.7). Referring to FIG. 7, the positive plate 101 includes a positivepattern 190 formed on its first side 180. As illustrated in FIG. 7, thepositive plate 101 is oriented with its corner C1 positioned in an upperleft position when the first side 180 is facing forwardly (or toward thefirst end cap 146 illustrated in FIGS. 3-4B, 16, 23, and 24). Thepositive pattern 190 includes four lines 191-194 that extend from thethrough-holes 171-174, respectively, to the through-hole 175. In theembodiment illustrated, the lines 191-194 intersect at a point on theedge of the through-hole 175. The lines 191-194 induce flow toward thethrough-hole 175 in a first flow direction identified by an arrow A1.Each of the lines 191-194 may be formed as a continuous line or by aplurality of through-holes arranged in a series to define the line. Theplurality of through-holes may each have a diameter of about 1millimeter (“mm”) to about 2 mm.

As mentioned above, each of the negative plates 142-NA and 142-NB (seeFIGS. 4A and 5) may be implemented as the negative plate 102 (see FIG.8). Referring to FIG. 8, the negative plate 102 includes a negativepattern 200 formed on its second side 182. As illustrated in FIG. 8, thenegative plate 102 is oriented with its corner C1 positioned in an upperright position when the second side 182 is facing forwardly (or towardthe first end cap 146 illustrated in FIGS. 3-4B, 16, 23, and 24). Thenegative pattern 200 includes four lines 201-204 that extend from thethrough-holes 171-174, respectively, to the through-hole 175. In theembodiment illustrated, the lines 201-204 intersect at a point on theedge of the through-hole 175. The lines 201-204 induce flow toward thethrough-hole 175 in a second flow direction identified by an arrow A2.Each of the lines 201-204 may be formed as a continuous line or by aplurality of through-holes arranged in a series to define the line. Theplurality of through-holes may each have a diameter of about 1 mm toabout 2 mm. When the plurality of through-holes are used to define thelines 191-194 (see FIG. 7) on the first side 180, the plurality ofthrough-holes also define the lines 201-204 on the second side 182.Thus, the positive plate 101 (see FIG. 7) and the negative plate 102 maysimply be mirror images of one another.

As mentioned above, each of the first neutral plates 142-N1, 142-N3,142-N5, 142-N7, 142-N9, and 142-N11 may be implemented as the firstneutral plate 103 (see FIG. 9). Referring to FIG. 9, the first neutralplate 103 includes a first neutral pattern 210 formed on its first side180. The first neutral plate 103 is oriented with its corner C1positioned in a lower right position when the first side 180 is facingforwardly (or toward the first end cap 146 illustrated in FIGS. 3-4B,16, 23, and 24). The first neutral pattern 210 includes six lines211-216. The lines 213-216 extend outwardly from a first intersectionpoint 217. By way of non-limiting examples, the first intersection point217 may be positioned about 2.0 cm above the edge E1 and about 4.8 cmaway from the edge E4. The lines 215 and 216 extend outwardly from thefirst intersection point 217 and form a V-shape. The line 216 extendsfrom the first intersection point 217 to the through-hole 175. The line216 may extend through the through-hole 175 and to the edge E4 or mayterminate between the through-hole 175 and the edge E4. The lines 213and 214 extend from the first intersection point 217 to thethrough-holes 173 and 174, respectively. The line 215 extends from thefirst intersection point 217 to a termination point 218. By way ofnon-limiting examples, the termination point 218 may be positioned about4.5 cm above the edge E1 and about 1.5 cm away from the edge E2. Thelines 211 and 212 extend from the line 215 to the through-holes 171 and172, respectively. The lines 211 and 212 may each be substantiallyparallel to the edges E2 and E4. The lines 211-216 induce an upward flowtoward the through-holes 171-174 in a third flow direction identified byan arrow A3. The third flow direction may be substantially parallel tothe edges E2 and E4. Each of the lines 211-216 may be formed as acontinuous line or by a plurality of through-holes arranged in a seriesto define the line. The plurality of through-holes may each have adiameter of about 1 mm to about 2 mm.

As mentioned above, each of the second neutral plates 142-N2, 142-N4,142-N6, 142-N8, 142-N10, and 142-N12 may be implemented as the secondneutral plate 104 (see FIG. 10). Referring to FIG. 10, the secondneutral plate 104 includes a second neutral pattern 220 formed on itssecond side 182. The second neutral plate 104 is oriented with itscorner C1 positioned in a lower left position when the second side 182is facing forwardly (or toward the first end cap 146 illustrated inFIGS. 3-4B, 16, 23, and 24). The second neutral pattern 220 includes sixlines 221-226. The lines 223, 225, and 226 extend outwardly from asecond intersection point 227. By way of non-limiting examples, thesecond intersection point 227 may be positioned about 2.0 cm above theedge E1 and about 4.8 cm away from the edge E4. The lines 225 and 226extend outwardly from the second intersection point 227 and form aV-shape. The line 226 extends from the second intersection point 227 tothe through-hole 175. The line 226 may extend through the through-hole175 and to the edge E4 or may terminate between the through-hole 175 andthe edge E4. The line 223 extends from the second intersection point 227to the through-hole 173. The line 225 extends from the secondintersection point 227 to the edge E2. The lines 221 and 222 extend fromthe line 225 to the through-holes 171 and 172, respectively. The lines221 and 222 may each be substantially parallel to the edges E2 and E4.The line 224 extends from the line 226 to the through-holes 174. Theline 224 intersects the line 226 at a location between the secondintersection point 227 and the through-hole 175. The lines 221-226induce an upward flow toward the through-holes 171-174 in a fourth flowdirection identified by an arrow A4. The fourth flow direction may besubstantially parallel to the edges E2 and E4. Each of the lines 221-226may be formed as a continuous line or by a plurality of through-holesarranged in a series to define the line. The plurality of through-holesmay each have a diameter of about 1 mm to about 2 mm. When the pluralityof through-holes are used to define the lines 211-216 (see FIG. 7) onthe first side 180, the plurality of through-holes also define the lines221-226 on the second side 182. Thus, the first neutral plate 103 (seeFIG. 9) and the second neutral plate 104 may simply be mirror images ofone another.

A first embodiment of the seals 144 is illustrated in FIGS. 4A, 5, and11. In the embodiment illustrated, each of the seals 144 is generallyplanar. Referring to FIG. 4A, the seals 144 help define a sealedinternal chamber 228 inside the cell 140A. The sealed internal chamber228 may be characterized as being an electrolysis chamber because theplates 142 split the water (see FIGS. 1-3) inside the sealed internalchamber 228. Referring to FIG. 11, each of the seals 144 has aperipheral portion 229 that defines an interior shape 230, which isclosed along the peripheral portion 229 of the seal. Referring to FIG.5, each of the seals 144 has a front side 231 opposite a back side 232.The interior shape 230 (see FIGS. 11 and 21) is open along both thefront and back sides 231 and 232. Referring to FIG. 4A, an interstitialspace 234 is defined between each adjacent pair of plates within theseries of plates 142. One of the seals 144 is positioned within each ofthe interstitial spaces 234. For example, one of the seals 144 ispositioned in the interstitial space 234 defined between the plates142-PA and 142-N1. The seals 144 are configured such that thethrough-holes 171-175 (see FIGS. 6-10) of each of the plates 142 arepositioned within the interior shape 230 (see FIGS. 11 and 21) of any ofthe seals 144 positioned alongside the plate. Thus, the interior shapes230 (see FIGS. 11 and 21) of the seals 144 are interconnected inside thecell 140A by one or more of the through-holes 170 (see FIGS. 6-10,12-15, and 17-20) and define the sealed internal chamber 228.

Referring to FIG. 4B, an interstitial space 236 may be defined betweenthe first end cap 146 and the positive plate 142-PA. One of the seals144, identified with reference numeral 144A, may be positioned in theinterstitial space 236. The seal 144A is positioned such that thethrough-holes 171-175 (see FIGS. 6-10) of the positive plate 142-PA arepositioned within the interior shape 230 (see FIGS. 11 and 21) of theseal 144A. Thus, the interior shape 230 (see FIGS. 11 and 21) of theseal 144A may be considered to be part of the sealed internal chamber228.

Similarly, an interstitial space 238 may be defined between the secondend cap 148 and the negative plate 142-NB. One of the seals 144,identified with reference numeral 144B in FIG. 5, may be positioned inthe interstitial space 238. The seal 144B (see FIG. 5) is positionedsuch that the through-holes 171-175 (see FIGS. 6-10) of the negativeplate 142-NB are positioned within the interior shape 230 (see FIGS. 11and 21) of the seal 144B. Thus, the interior shape 230 (see FIGS. 11 and21) of the seal 144B (see FIG. 5) may be considered to be part of thesealed internal chamber 228.

Referring to FIG. 4A, the seals 144 are substantially electricallynon-conductive, and electrically isolate the plates 142 from oneanother. Thus, within the cell 140A, current flows between the plates142 through the water 116 (see FIGS. 1-3). By way of a non-limitingexample, the seals 144 may each be constructed from styrene-butadienerubber (“SBR”), silicone, and the like.

As is apparent to those of ordinary skill in the art, the hydrogen gas120 (see FIG. 2) will collect along the negative plates 142-NA and142-NB and the oxygen gas 121 (see FIG. 2) will collect along thepositive plates 142-PA and 142-PB. Referring to FIG. 3, the hydrogen andoxygen gases 120 and 121 (see FIG. 2) are both lighter than the water116 and collect near the top of the sealed internal chamber 228 (seeFIGS. 4A and 4B). Additionally, the hydrogen gas 120 (see FIG. 2) islighter than the oxygen gas 121 (see FIG. 2). Thus, the hydrogen gas 120(see FIG. 2) may collect nearer the top of the sealed internal chamber228 (see FIGS. 4A and 4B) than the oxygen gas 121 (see FIG. 2). Each ofthe flows identified by the arrows A1-A4 in FIGS. 7-10, respectively,may be directed toward the near the top of the sealed internal chamber228 (see FIGS. 4A and 4B).

Referring to FIG. 4A, the cell 140A has at least one water inlet, suchas a water inlet 240, through which the water 116 (see FIGS. 1-3) entersthe sealed internal chamber 228 of the cell 140A. In the embodimentillustrated, the water inlet 240 is formed in the first end cap 146.Thus, the water inlet 240 is in fluid communication with the sealedinternal chamber 228. The water 116 (see FIGS. 1-3) flows from the waterinlet 240 toward the second end cap 148. The water 116 (see FIGS. 1-3)flows through the through-holes 170 (see FIGS. 6-10, 12-15, and 17-20)in the plates 142 and into the interior shapes 230 (see FIGS. 11 and 21)of the seals 144 (see FIGS. 4A, 5, and 11) positioned between eachadjacent pair of plates. The first end cap 146 includes a plurality ofthrough-holes 242 (see FIG. 4B) through which the ties 152 may extend.

The cell 140A has at least one hydrogen outlet, such as a hydrogenoutlet 244, through which the hydrogen gas 120 (see FIG. 2) exits thesealed internal chamber 228 of the cell 140A (e.g., and enters thehydrogen gas line(s) 128 illustrated in FIGS. 1 and 3). In theembodiment illustrated, the hydrogen outlet 244 is formed in second endcap 148. Thus, the hydrogen outlet 244 is in fluid communication withthe sealed internal chamber 228. The hydrogen gas 120 (see FIG. 2) flowsfrom the negative plates 142-NA and 142-NB toward the second end cap148. Like the water 116 (see FIGS. 1-3), the hydrogen gas 120 (see FIG.2) flows through the through-holes 170 (see FIGS. 6-10, 12-15, and17-20) in the plates 142 and into the interior shapes 230 (see FIGS. 11and 21) of the seals 144 positioned between each adjacent pair ofplates. By way of a non-limiting example, the hydrogen outlet 244 may bethreaded with ¼ National Pipe Thread Taper (“NPT”) threads configured toreceive a 10 mm quick connector. The oxygen gas 121 (see FIG. 2) mayexit through the hydrogen outlet 244 or be vented into the surroundingenvironment via one or more check valves (not shown) formed in thesecond end cap 148. The second end cap 148 includes a plurality ofthrough-holes 246 (see FIG. 4B) through which the ties 152 may extend.The first and second end caps 146 and 148 are each constructed from asubstantially electrically non-conductive material. By way of anon-limiting example, the first and second end caps 146 and 148 may beconstructed from plastic (e.g., nylon, acrylonitrile Butadiene Styrene(“ABS”), etc.) and the like.

Referring to FIG. 3, the positive terminal T+ of the power controller108 is connected (e.g., by one of the conductors 110) to the positiveplates 142-PA and 142-PB (see FIGS. 4A-5). Referring to FIG. 4B, in theembodiment illustrated, an optional positive conductor 250 (e.g., abolt) is inserted through the optional through-hole 178 (see FIGS. 6-10,12-15, and 17-20) of the positive plates 142-PA and 142-PB. Referring toFIG. 3, the positive terminal T+ of the power controller 108 isconnected (e.g., by one of the conductors 110) to the positive conductor250. Referring to FIG. 4A, the cutout 161B (see FIG. 6) of the negativeplates 142-NA and 142-NB prevents the positive conductor 250 fromcontacting the negative plates 142-NA and 142-NB. Similarly, referringto FIG. 5, the cutout 161C (see FIG. 6) of the neutral plates 142-N1,142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 prevents the positiveconductor 250 (see FIGS. 3-4B) from contacting the neutral plates142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11. Additionally, thecutout 161D (see FIG. 6) of the neutral plates 142-N2, 142-N4, 142-N6,142-N8, 142-N10, and 142-N12 prevents the positive conductor 250 (seeFIGS. 3-4B) from contacting the neutral plates 142-N2, 142-N4, 142-N6,142-N8, 142-N10, and 142-N12.

Referring to FIG. 3, the negative terminal T− of the power controller108 is connected to the negative plates 142-NA and 142-NB (see FIGS.4A-5). Referring to FIG. 4A, in the embodiment illustrated, an optionalnegative conductor 252 (e.g., a bolt) is inserted through thethrough-hole 178 (see FIGS. 6-10, 12-15, and 17-20) of the negativeplates 142-NA and 142-NB.

Referring to FIG. 3, the negative terminal T− of the power controller108 is connected to the negative conductor 252 (e.g., by one of theconductors 110). Referring to FIG. 4A, the cutout 161B (see FIG. 6) ofthe positive plates 142-PA and 142-PB prevents the negative conductor252 from contacting the positive plates 142-PA and 142-PB. Similarly,referring to FIG. 5, the cutout 161D (see FIG. 6) of the neutral plates142-N1, 142-N3, 142-N5, 142-N7, 142-N9, and 142-N11 prevents thenegative conductor 252 from contacting the neutral plates 142-N1,142-N3, 142-N5, 142-N7, 142-N9, and 142-N11. Additionally, the cutout161C (see FIG. 6) of the neutral plates 142-N2, 142-N4, 142-N6, 142-N8,142-N10, and 142-N12 prevents the negative conductor 252 from contactingthe neutral plates 142-N2, 142-N4, 142-N6, 142-N8, 142-N10, and 142-N12.

Referring to FIG. 4A, the water 116 (see FIGS. 1-3) inside the cell 140Aconnects the positive plates 142-PA and 142-PB and the negative plates142-NA and 142-NB to form a circuit. Referring to FIG. 3, the flow ofcurrent through the water 116 causes the water molecules 117 (see FIG.2) to split into the hydrogen atoms 118 (see FIG. 2) and the oxygenatoms 119 (see FIG. 2). In other words, the electrolysis performed bythe cell 140A is powered by the power controller 108.

Referring to FIG. 5, optionally, a first ground conductor (not shown)may be inserted through the through-hole 178 (see FIGS. 6-10, 12-15, and17-20) of the first neutral plates 142-N1, 142-N3, 142-N5, 142-N7,142-N9, and 142-N11. Similarly, a second ground conductor (not shown)may be inserted through the through-hole 178 (see FIGS. 6-10, 12-15, and17-20) of the second neutral plates 142-N2, 142-N4, 142-N6, 142-N8,142-N10, and 142-N12. The first and second ground conductors (not shown)may each be connected to ground and do not contact either the positiveplates 142-PA and 142-PB or the negative plates 142-NA and 142-NB.

Thus, the cell 140A (see FIGS. 1 and 3-4B) may be configured as follows:

-   -   1. the positive plate 142-PA oriented with its through-hole 178        (see FIGS. 6-10, 12-15, and 17-20) positioned top left and        connected to the positive conductor 250 (see FIG. 3-4B);    -   2. the neutral plates 142-N1 to 142-N4 (optionally, the first        neutral plates 142-N1 and 142-N3 may be connected to the first        ground conductor (not shown) and the second neutral plates        142-N2 and 142-N4 may be connected to the second ground        conductor (not shown));    -   3. the negative plate 142-NA oriented with its through-hole 178        positioned top right and connected to the negative conductor        252;    -   4. the neutral plates 142-N5 to 142-N8 (optionally, the first        neutral plates 142-N5 and 142-N7 may be connected to the first        ground conductor (not shown) and the second neutral plates        142-N6 and 142-N8 may be connected to the second ground        conductor (not shown));    -   5. the positive plate 142-PB oriented with its through-hole 178        positioned top left and connected to the positive conductor 250;    -   6. the neutral plates 142-N9 to 142-N12 (optionally, the first        neutral plates 142-N9 and 142-N11 may be connected to the first        ground conductor (not shown) and the second neutral plates        142-N10 and 142-N12 may be connected to the second ground        conductor (not shown)); and    -   7. the negative plate 142-NB oriented with its through-hole 178        positioned top right and connected to the negative conductor        252.

The positive plates 142-PA and 142-PB create an electric arc with thenegative plates 142-NA and 142-NB that is driven by the water 116 (seeFIGS. 1-3). The neutral plates 142-N1 to 142-N12 create resistancebetween the positive plates 142-PA and 142-PB and the negative plates142-NA and 142-NB and increase the flow of current (e.g., measured inamperes).

Referring to FIG. 4A, in the embodiment illustrated, the ties 152 (e.g.,threaded rods) are configured to connect the first and second end caps146 and 148 together with the plates 142 and seals 144 positionedtherebetween. The ties 152 extend alongside and substantiallyperpendicular to the edges E1-E4 (see FIG. 6) of the plates 142.Referring to FIG. 6, the cutouts 162A and 162B on the edges E1 and E3and the cutouts 163A-163C on the edges E2 and E4 are each configured toreceive a portion of a different one of the ties 152 (see FIGS. 3-4B).Referring to FIG. 4A, the ties 152 may be constructed from asubstantially electrically non-conductive material or may be wrapped ina substantially electrically non-conductive material 153. Thus, the ties152 do not conduct electricity between the plates 142. The ties 152 helpprevent the plates 142 from moving inside the cell 140A and helpmaintain their positioning inside the cell 140A. The seals 144 are eachpositioned inwardly of the ties 152, which do not extend through theclosed interior shapes 230 (see FIGS. 11 and 21) of the seals 144.

The ties 152 are configured to compress the seals 144 inside the cell140A to help ensure that the water 116 (see FIGS. 1-3) and/or thehydrogen gas 120 (see FIG. 2) does not leak from the cell 140A. In theembodiment illustrated, the ties 152 have been implemented as threadedrods surrounded by the substantially electrically non-conductivematerial 153. The fasteners 154 (e.g., nuts) are threaded onto the endsof the threaded rods alongside each of the first and second end caps 146and 148. By tightening the fasteners 154, sufficient pressure may beapplied to the first and second end caps 146 and 148 to compress theseals 144 and prevent leakage.

As mentioned above, referring to FIG. 1, the water 116 may include thecatalyst 122 (e.g., potassium hydroxide), which reacts with theelectricity and increases the flow of current (e.g., measured inamperes). Referring to FIG. 2, increasing the current splits more of thewater molecules 117 into the hydrogen and oxygen atoms 118 and 119.Referring to FIG. 3, by way of a non-limiting example, the cell 140A maybe configured to generate about 1.3 liters per minute of hydrogen gas.Referring to FIG. 1, if the hydrogen consuming process and/or device 134requires less hydrogen, the excess hydrogen may simply be vented to theoutside environment. By not storing the excess hydrogen, the system 100avoids potential explosion risks associated with storing hydrogen.

Referring to FIG. 4A, in alternate embodiments, different numbers ofneutral plates may be positioned between the positive and negativeplates 101 (see FIG. 7) and 102 (see FIG. 8) of the cell 140A. Forexample, the cell 140A may include fifteen neutral plates and beconfigured as follows:

-   -   1. a first positive plate (like the positive plate 101        illustrated in FIG. 7);    -   2. a first neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   3. a second neutral plate (like the second neutral plate 104        illustrated in FIG. 10);    -   4. a third neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   5. a fourth neutral plate (like the second neutral plate 104        illustrated in FIG. 10);    -   6. a fifth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   7. a first negative plate (like the negative plate 102        illustrated in FIG. 8);    -   8. a sixth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   9. a seventh neutral plate (like the second neutral plate 104        illustrated in FIG. 10);    -   10. an eighth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   11. a ninth neutral plate (like the second neutral plate 104        illustrated in FIG. 10);    -   12. a tenth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   13. a second positive plate (like the positive plate 101        illustrated in FIG. 7);    -   14. an eleventh neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   15. a twelfth neutral plate (like the second neutral plate 104        illustrated in FIG. 10);    -   16. a thirteenth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   17. a fourteenth neutral plate (like the second neutral plate        104 illustrated in FIG. 10);    -   18. a fifteenth neutral plate (like the first neutral plate 103        illustrated in FIG. 9);    -   19. a second negative plate (like the negative plate 102        illustrated in FIG. 8).        Again, the two positive plates (each like the positive plate 101        illustrated in FIG. 7) create electric arcs with the two        negative plates (each like the negative plate 102 illustrated in        FIG. 8) that is driven by the water 116 (see FIGS. 1-3). The        fifteen neutral plates create resistance between the positive        plates and the negative plates and increase the flow of current.

High-Density Embodiment

FIGS. 12-15 illustrate second embodiments of the plates 142 (see FIGS.3-6, 16, and 23) that may be used to construct a high-density version ofthe cell 140A (see FIGS. 1 and 3-4B). The high-density version may beused to supply hydrogen to a flame consuming a very high number ofcalories (e.g., a furnace, an industrial oven, and the like). Oxygenproduced by the high-density version may be combined with the hydrogento increase the heat output of the flame.

In FIGS. 12-15, the through-holes 170 include only the through-holes 171and 175. In other words, the through-holes 172-174 are omitted. FIGS.12-15 illustrate plates 301-304, respectively.

Referring to FIG. 12, the positive plate 301 may be used to constructthe cell 140A (see FIGS. 1 and 3-4B) instead and in place of thepositive plate 101 (see FIG. 7). The positive plate 301 includes apositive pattern 310 instead of the positive pattern 190 (see FIG. 7).The positive pattern 310 is formed on the first side 180 of the positiveplate 301. The positive plate 301 is oriented with the corner C1positioned in the upper left position when the first side 180 is facingforwardly (or toward the first end cap 146 illustrated in FIGS. 3-4B,16, 23, and 24). The positive pattern 310 includes five lines 311-315.The line 311 extends from the through-hole 171 to the through-hole 175and the line 312 extends from the through-hole 171 to a first locationnear the through-hole 175. The line 315 extends outwardly from thethrough-hole 171 in a direction substantially parallel with the edge E3.The line 313 extends from the line 315 to a second location near thethrough-hole 175 and spaced apart from the first location. The line 314extends from the line 315 to the edge E4. The lines 311-315 areconfigured to induce flow toward the through-hole 175 in a fifth flowdirection identified by an arrow A5. Each of the lines 311-315 may beformed as a continuous line or by a plurality of through-holes arrangedin a series to define the line. The plurality of through-holes may eachhave a diameter of about 1 mm to about 2 mm.

Referring to FIG. 13, the negative plate 302 may be used to constructthe cell 140A (see FIGS. 1 and 3-4B) instead and in place of thenegative plate 102 (see FIG. 8). The negative plate 302 includes anegative pattern 320 instead of the negative pattern 200 (see FIG. 8).The negative pattern 320 is formed on the second side 182 of thenegative plate 302. The negative pattern 320 is oriented with the cornerC1 positioned in the upper right position when the second side 182 isfacing forwardly (or toward the first end cap 146 illustrated in FIGS.3-4B, 16, 23, and 24). The negative pattern 320 includes five lines321-325. The line 321 extends from the through-hole 171 to thethrough-hole 175 and the line 322 extends from the through-hole 171 to afirst location near the through-hole 175. The line 325 extends outwardlyfrom the through-hole 171 in a direction substantially parallel with theedge E3. The line 323 extends from the line 325 to a second locationnear the through-hole 175 and spaced apart from the first location. Theline 324 extends from the line 325 to the edge E4. Each of the lines321-325 may be formed as a continuous line or by a plurality ofthrough-holes arranged in a series to define the line. The plurality ofthrough-holes may each have a diameter of about 1 mm to about 2 mm. Thelines 321-325 are configured to induce flow toward the through-hole 175in a sixth flow direction identified by an arrow A6. When the pluralityof through-holes are used to define the lines 311-315 (see FIG. 12) onthe first side 180, the plurality of through-holes also define the lines321-325 on the second side 182. Thus, the positive plate 301 (see FIG.12) and the negative plate 302 may simply be mirror images of oneanother.

Referring to FIG. 14, the first neutral plate 303 may be used toconstruct the cell 140A (see FIGS. 1 and 3-4B) instead and in place ofthe first neutral plate 103 (see FIG. 9). The first neutral plate 303includes a first neutral pattern 330 instead of the first neutralpattern 210 (see FIG. 9). The first neutral pattern 330 is formed on thefirst side 180 of the first neutral plate 303. The first neutral plate303 is oriented with the corner C1 positioned in the lower rightposition when the first side 180 is facing forwardly (or toward thefirst end cap 146 illustrated in FIGS. 3-4B, 16, 23, and 24). The firstneutral pattern 330 includes three lines 331-333. The line 331 extendsfrom the through-hole 171 to the through-hole 175. The line 333 extendsinwardly from the edge E4 in a direction substantially parallel with theedge E1. The line 333 terminates near the through-hole 175. The line 332extends from the line 333 to the edge E2 or to a location near thethrough-hole 175. The lines 331-333 are configured to induce flow towardthe through-hole 171 in a seventh flow direction identified by an arrowA7. Each of the lines 331-333 may be formed as a continuous line or by aplurality of through-holes arranged in a series to define the line. Theplurality of through-holes may each have a diameter of about 1 mm toabout 2 mm.

Referring to FIG. 15, the second neutral plate 304 may be used toconstruct the cell 140A (see FIGS. 1 and 3-4B) instead and in place ofthe second neutral plate 104 (see FIG. 10). The second neutral plate 304includes a second neutral pattern 340 instead of the second neutralpattern 220 (see FIG. 10). The second neutral pattern 340 is formed onthe second side 182 of the second neutral plate 304. The second neutralplate 304 is oriented with the corner C1 positioned in the lower leftposition when the second side 182 is facing forwardly (or toward thefirst end cap 146 illustrated in FIGS. 3-4B, 16, 23, and 24). The secondneutral pattern 340 includes three lines 341-343. The line 341 extendsfrom the through-hole 171 to the through-hole 175. The line 343 extendsinwardly from the edge E4 in a direction substantially parallel with theedge E1. The line 343 terminates near the through-hole 175. The line 342extends from the line 343 to the edge E2 or to a location near thethrough-hole 171. The lines 341-343 are configured to induce flow towardthe through-hole 171 in an eighth flow direction identified by an arrowA8. Each of the lines 341-343 may be formed as a continuous line or by aplurality of through-holes arranged in a series to define the line. Theplurality of through-holes may each have a diameter of about 1 mm toabout 2 mm. When the plurality of through-holes are used to define thelines 331-333 (see FIG. 14) on the first side 180, the plurality ofthrough-holes also define the lines 341-343 on the second side 182.Thus, the first neutral plate 303 (see FIG. 9) and the second neutralplate 304 may simply be mirror images of one another.

Each of the flows identified by the arrows A5-A8 in FIGS. 12-15,respectively, may be directed toward the near the top of the sealedinternal chamber 228 (see FIGS. 4A and 4B). In the positive and negativeplates 301 and 302, the through-hole 171 may be characterized as beingan entrance or inlet and the through-hole 175 may be characterized asbeing an exit or outlet. The fifth and sixth flow directions (identifiedby the arrows A5 and A6) each flow from the inlet (the through-hole 171)toward the outlet (the through-hole 175). In the first and secondneutral plates 303 and 304, the through-hole 175 may be characterized asbeing an entrance or inlet and the through-hole 171 may be characterizedas being an exit or outlet. The seventh and eighth flow directions(identified by the arrows A7 and A8) each flow from the inlet (thethrough-hole 175) toward the outlet (the through-hole 171). Referring toFIGS. 12-15, when the plates 301-304 are used to construct the cell 140A(see FIGS. 1 and 3-4B), the flows induced by the fifth, sixth, seventh,and eighth flow directions cause the water 116 (see FIGS. 1-3), thehydrogen gas 120 (see FIG. 2), and/or the oxygen gas 121 (see FIG. 2) tozig-zag through the cell 140A. Thus, fewer ones of the through-holes 170are needed to create the desired flows.

Low-Density Embodiment

FIG. 16 is a perspective view of a cell 350 that is a low-densityversion of the cell 140A (see FIGS. 1 and 3-4B). The cell 350 may beused to supply hydrogen to a low-density application, such as a flameconsuming a low number of calories (e.g., a residential oven, a lamp,and the like). Oxygen produced by the low-density version may be ventedto the atmosphere. Like the cell 140A (see FIGS. 1 and 3-4B), the cell350 includes the plates 142 but the seals 144 are replaced with seals352 (see FIGS. 21 and 23) and membranes 354 (see FIG. 22). In theembodiment illustrated, the water inlet 240 (see FIGS. 4A and 4B), thehydrogen outlet 244 (see FIGS. 4A, 4B, 23, and 24), and a separateoxygen outlet 362 (see FIGS. 23 and 24) are formed in the second end cap148. In alternate embodiments, the second end cap 148 may include two ormore separate water inlets that are each like the water inlet 240 (seeFIGS. 4A and 4B) and connected to the water source 112 (see FIGS. 1 and3) by the water line(s) 114 (see FIGS. 1 and 3). In alternateembodiments, the first end cap 146 may include the water inlet 240 (seeFIGS. 4A and 4B) or two or more separate water inlets that are each likethe water inlet 240 and connected to the water source 112 (see FIGS. 1and 3) by the water line(s) 114 (see FIGS. 1 and 3). Optionally,referring to FIG. 23, the hydrogen outlet 244 may be positioned abovethe oxygen outlet 362. In the embodiment illustrated, the hydrogenoutlet 244 and the oxygen outlet 362 are spaced apart from one anotherand arranged side-by-side.

Referring to FIG. 16, fittings 364-368 may be connected to the waterinlet 240 (see FIGS. 4A and 4B), the hydrogen outlet 244 (see FIGS. 4A,4B, 23, and 24), and the oxygen outlet 362 (see FIGS. 23 and 24),respectively. The fitting 364 is configured to be coupled to the waterline(s) 114 (see FIGS. 1 and 3) and to supply the water 116 (see FIGS.1-3) received therethrough from the water source 112 (see FIGS. 1 and 3)to a sealed interior 370 (see FIGS. 23 and 24) of the cell 350. Thefitting 366 is configured to be coupled to the hydrogen gas line(s) 128(see FIGS. 1 and 3) and to conduct the hydrogen gas 120 (see FIG. 2)produced by the cell 350 to the hydrogen reservoir 130 (see FIG. 1). Thefitting 368 is configured to be coupled to the oxygen gas line(s) 138(see FIG. 1) and to vent the oxygen gas 121 (see FIG. 2) produced by thecell 350 to the atmosphere.

FIGS. 17-20 illustrate plates 401-404, respectively, that together are athird embodiment of the plates 142 (see FIGS. 3-6, 16, and 23) and maybe used to construct the cell 350 (see FIGS. 16, 23, and 24). As shownin FIGS. 17-20, none of the plates 401-404 includes a pattern of lines.

In FIGS. 17-20, the through-holes 170 include only the through-holes171, 174, 175, and 176. In other words, the through-holes 172 and 173are omitted. The through-hole 171 may be positioned directly below thethrough-hole 176 and directly across from the through-hole 174. Thethrough-hole 175 may be positioned directly above the through-hole 174and directly across from the through-hole 176. Thus, the through-holes171, 174, 175, and 176 may be positioned at corners of rectangularshape.

Referring to FIG. 17, the positive plate 401 is oriented with its cornerC1 positioned in the upper left position when the first side 180 isfacing forwardly (or toward the first end cap 146 illustrated in FIGS.3-4B, 16, 23, and 24). A flow may be induced along the first side 180toward the through-hole 175 in a ninth flow direction identified by anarrow A9. Referring to FIG. 3, the positive conductor 250 (e.g., a bolt)may be inserted through the through-hole 178 of the positive plate 401(see FIG. 17) and connected (e.g., by one of the conductors 110) to thepositive terminal T+ of the power controller 108. In this manner, thepositive plate 401 (see FIG. 17) may be charged. Alternatively, one ofthe conductors 110 may direct couple the positive plate 401 (see FIG.17) to the positive terminal T+ of the power controller 108.

Referring to FIG. 18, the negative plate 402 is oriented with the cornerC1 positioned in the upper right position when the second side 182 isfacing forwardly (or toward the first end cap 146 illustrated in FIGS.3-4B, 16, 23, and 24). A flow may be induced along the second side 182toward the through-hole 175 in a tenth flow direction identified by anarrow A10. Referring to FIG. 3, the negative conductor 252 (e.g., abolt) may be inserted through the through-hole 178 of the negative plate402 (see FIGS. 18 and 23) and connected (e.g., by one of the conductors110) to the negative terminal T− of the power controller 108. In thismanner, the negative plate 402 (see FIGS. 18 and 23) may be charged.Alternatively, one of the conductors 110 may direct couple the negativeplate 402 (see FIGS. 18 and 23) to the negative terminal T− of the powercontroller 108.

Referring to FIG. 19, the first neutral plate 403 is oriented with thecorner C1 positioned in the lower right position when the first side 180is facing forwardly (or toward the first end cap 146 illustrated inFIGS. 3-4B, 16, 23, and 24). A flow may be induced along the first side180 toward the through-hole 171 in an eleventh flow direction identifiedby an arrow A11.

Referring to FIG. 20, the second neutral plate 404 is oriented with thecorner C1 positioned in the lower left position when the second side 182is facing forwardly (or toward the first end cap 146 illustrated inFIGS. 3-4B, 16, 23, and 24). A flow may be induced along the second side182 toward the through-hole 171 in a twelfth flow direction identifiedby an arrow A12.

Referring to FIG. 21, the seals 352 are substantially similar to theseals 144 (see FIGS. 4A, 5, and 11). Thus, each of the seals 352includes the peripheral portion 229 that defines the interior shape 230,which is closed along the peripheral portion 229 of the seal. Each ofthe seals 352 also has the front side 231 opposite the back side 232(see FIGS. 5, 11, and 24). Further, each of the seals 352 may begenerally planar. However, the seals 352 differ from the seals 144 (seeFIGS. 4A, 5, and 11) because each of the seals 352 include first andsecond barriers 410 and 412 that define first and second sealed regions420 and 422, respectively, within the interior shape 230. The firstsealed region 420 is sealed by the first barrier 410 and the peripheralportion 229. The second sealed region 422 is sealed by the secondbarrier 412 and the peripheral portion 229. The first and second sealedregions 420 and 422 are positioned to isolate two of the through-holes170 (see FIGS. 6-10, 12-15, and 17-20) of each of the plates 401-404(see FIGS. 17-20, respectively) from a remainder 424 of the interiorshape 230.

FIG. 22 illustrates one of the membranes 354. Each of the membranes 354may be generally planar. As shown in FIG. 22, the membrane 354 may havethe same general outer shape as the plates 142 (see FIGS. 3-6, 16, and23). The membranes 354 each include through-holes 470 that correspond tothe through-holes 170 (see FIGS. 6-10, 12-15, and 17-20) of the plates401-404 illustrated in FIGS. 17-20, respectively. Thus, referring toFIG. 17, the through-holes 470 (see FIG. 22) each include through-holes471 and 474-476 (see FIG. 22) that correspond to the through-holes 171and 174-176, respectively. The through-holes 470 are configured to allowthe water 116 (see FIGS. 1-3), the hydrogen gas 120 (see FIG. 2), andthe oxygen gas 121 (see FIG. 2) to flow therethrough. Each of themembranes 354 is configured to be sandwiched between a pair of the seals352 (see FIGS. 21 and 23) and to permit flow between the pair of sealsonly through the through-holes 470. By way of a non-limiting example,the membranes 354 (see FIG. 22) may each be constructed from vinyl or asimilar material configured to block oxygen and hydrogen from flowingthrough the material.

FIG. 21 illustrates the seal 352 in a first orientation with its firstand second sealed regions 420 and 422 positioned in the upper right handand lower left hand corners, respectively. In this orientation, thefront side 231 faces toward the first end cap 146 (see FIGS. 3-4B, 16,23, and 24). The seal 352 may be positioned in a second orientation inwhich the front side 231 faces toward the second end cap 148 (see FIGS.3-4B, 16, 23, and 24). In the second orientation, the first and secondsealed regions 420 and 422 are positioned in the upper left hand andlower right hand corners, respectively. Table A below lists which of thethrough-holes 170 (see FIGS. 6-10, 12-15, and 17-20) of each of theplates 401-404 (see FIGS. 17-20, respectively) is positioned inside eachof the first and second sealed regions 420 and 422 when the seal 352 ispositioned alongside the plate in the first and second orientations. Forexample, when the seal 352 is positioned alongside the positive plate401 (see FIG. 17) in the first orientation, the through-holes 176 and174 are positioned inside the first and second sealed regions 420 and422, respectively. On the other hand, when the seal 352 is positionedalongside the positive plate 401 (see FIG. 17) in the secondorientation, the through-holes 175 and 171 are positioned inside thefirst and second sealed regions 420 and 422, respectively.

TABLE A Orientation of Seal 352 First Orientation (Shown in FIG. 21)Second Orientation First sealed Second sealed First sealed Second sealedregion 420 region 422 region 420 region 422 Positive through-holethrough-hole through-hole through-hole plate 401 176 174 175 171Negative through-hole through-hole through-hole through-hole plate 402175 171 176 174 First through-hole through-hole through-holethrough-hole neutral 174 176 171 175 plate 403 Second through-holethrough-hole through-hole through-hole neutral 171 175 174 176 plate 404Membrane through-hole through-hole through-hole through-hole 354 476 474475 471

Table A above also lists which of the through-holes 470 (see FIG. 22) ofthe membrane 354 (see FIG. 22) is positioned inside each of the firstand second sealed regions 420 and 422 when the seal 352 is positionedalongside the membrane 354 in the first and second orientations. Forexample, when the seal 352 is positioned alongside the membrane 354 (seeFIG. 22) in the first orientation, the through-holes 476 and 474 arepositioned inside the first and second sealed regions 420 and 422,respectively. On the other hand, when the seal 352 is positionedalongside the membrane 354 (see FIG. 22) in the second orientation, thethrough-holes 475 and 471 are positioned inside the first and secondsealed regions 420 and 422, respectively.

FIG. 23 illustrates an exemplary slice 430 through the cell 350, whichis also illustrated in FIGS. 16 and 24. Referring to FIG. 23, the slice430 includes the first end cap 146, the second end cap 148, the plates142, the seals 352, and the membranes 354 (see FIG. 22). In thisembodiment, the plates 142 include positive plates 401A and 401B, thenegative plate 402, first neutral plates 403A-403D, second neutralplates 404A-404C. The positive plates 401A and 401B are each like thepositive plate 401 (see FIG. 17). The first neutral plates 403A-403D areeach like the first neutral plate 403 (see FIG. 19). The second neutralplates 404A-404C are each like the second neutral plate 404 (see FIG.20). The seals 352 include seals 352A-352Q and the membranes 354 (seeFIG. 22) include membranes 354A-354F. In the embodiment illustrated, thefirst end cap 146, the second end cap 148, the plates 142, the seals352, and the membranes 354 (see FIG. 22) are arranged in the followingorder:

1. the first end cap 146;

2. the seal 352A (in the first orientation);

3. the positive plate 401A;

4. the seal 352B (in the first orientation);

5. the second neutral plate 404A;

6. the seal 352C (in the second orientation);

7. the membrane 354A;

8. the seal 352D (in the first orientation);

9. the first neutral plate 403A;

10. the seal 352E (in the second orientation);

11. the membrane 354B;

12. the seal 352F (in the first orientation);

13. the second neutral plate 404B;

14. the seal 352G (in the second orientation);

15. the membrane 354C;

16. the seal 352H (in the first orientation);

17. the first neutral plate 403B;

18. the seal 352I (in the second orientation);

19. the negative plate 402;

20. the seal 352J (in the first orientation);

21. the membrane 354D;

22. the seal 352K (in the second orientation);

23. the first neutral plate 403C;

24. the seal 352L (in the first orientation);

25. the membrane 354E;

26. the seal 352M (in the second orientation);

27. the second neutral plate 404C;

28. the seal 352N (in the first orientation);

29. the membrane 354F;

30. the seal 352O (in the second orientation);

31. the first neutral plate 403D;

32. the seal 352P (in the first orientation);

33. the positive plate 401B;

34. the seal 352Q (in the first orientation); and

35. the second end cap 148

As shown in FIG. 24, the seals 352A-352Q define a first gas chamber 432(shown using hash marks) and a second gas chamber 434 in the cell 350.The first and second gas chambers 432 and 434 are isolated from oneanother. The first gas chamber 432 (shown using hash marks) maytemporarily house the oxygen gas 121 (see FIG. 2) and conduct it to theoxygen outlet 362. The second gas chamber 434 may temporarily house thehydrogen gas 120 (see FIG. 2) and conduct it to the hydrogen outlet 244.As shown in FIG. 23, one side of each of the negative plate 402, thefirst neutral plates 403A-403D, the second neutral plates 404A-404C, andthe membranes 354A-354F is positioned in the first gas chamber 432 (seeFIG. 24) and the other side of each of these structures is positioned inthe second gas chamber 434 (see FIG. 24).

As explained above and shown in FIG. 24, the seals 352A-352Q cause thewater 116 (see FIGS. 1-3) and the oxygen gas 121 (see FIG. 2) to zigzagthrough the first gas chamber 432 and the water 116 and the hydrogen gas120 (see FIG. 2) to zig-zag through the second gas chamber 434. Thus,fewer ones of the through-holes 170 (see FIGS. 6-10, 12-15, and 17-20)are needed to create the desired flows. As mentioned above, the cell 350may include more than one water inlet like the water inlet 240 (seeFIGS. 4A and 4B). In such embodiments, at least one of the water inletsmay open into the first gas chamber 432 and at least one of the waterinlets may open into the second gas chamber 434.

Referring to FIG. 21, the seals 352 may be constructed from any materialsuitable for constructing the seals 144 (see FIGS. 4A, 5, and 11). Inalternate embodiments, the seals 144 may be used with the plates401-404. In such embodiments, additional seals (e.g., O-rings) may beused to block or isolate at least two of the through-holes 170 of theplates 401-404 as described above.

Power Controller

FIG. 25 illustrates an exemplary implementation of the power controller108 connected to the hydrogen generator 106 by the electrical conductors110. As mentioned above, the power controller 108 may be connected tothe power source 109 (see FIG. 1), which may be implemented as an ACsource (e.g., a conventional wall socket). Thus, the power controller108 has positive and negative contacts 502 and 504 configured to beconnected to the power source 109 (see FIG. 1). By way of a non-limitingexample, the positive and negative contacts 502 and 504 may becomponents of a conventional plug configured to plug into a conventional(110 V) AC wall outlet. The AC is conducted to a rectifier 510 thatconverts the AC to DC. Conductors 512 and 514 conduct the DC to thepositive and negative terminals T+ and T−, respectively.

In the embodiment illustrated, the negative contact 504 is connected tothe rectifier 510 by a conductor 516. The positive contact 502 isconnected by a conductor 518 to a solid-state relay 520. The solid-staterelay 520 is connected to the rectifier 510 by a conductor 522. Thesolid-state relay 520 includes a potentiometer 530 that is used todetermine the voltage of the AC input into the rectifier 510. Thepotentiometer 530 is connected to an interface 532 that may be operatedmanually (e.g., a dial) or by a computing device (not shown). Theinterface 532 controls the potentiometer 530 and determines the voltageof the AC input into the rectifier 510. The voltage of the DC output bythe rectifier 510 depends upon the voltage of the AC input into therectifier 510. Thus, by controlling the voltage of the AC input into therectifier 510, the potentiometer 530 determines the voltage of the DCoutput by the rectifier 510.

The voltage of the DC output by the rectifier 510 determines at least inpart the amount of hydrogen gas output by the hydrogen generator 106.

Hydrogen Consuming Process and/or Device

Referring to FIG. 1, the hydrogen consuming process and/or device 134may be any process or device configured to use or consume the hydrogengas 120 (see FIG. 2). Optionally, the hydrogen consuming process and/ordevice 134 may use or consume the oxygen gas 121 (see FIG. 2) with thehydrogen gas 120 (see FIG. 2).

The hydrogen consuming process and/or device 134 may be implemented as ahydrogenation process. By way of another non-limiting example, thehydrogen consuming process and/or device 134 may be any deviceconfigured to produce an explosion. For example, the hydrogen consumingprocess and/or device 134 may be implemented as an internal combustionengine (e.g., a diesel engine or a gasoline engine). Such an internalcombustion engine may be incorporated into a vehicle (e.g., a car, atruck, a motorcycle, a tractor, a bus, a semi-trailer truck, a boat, anairplane, a train, etc.). By way of yet another non-limiting example,the hydrogen consuming process and/or device 134 may be any deviceconfigured to produce a flame used to produce heat and/or light. Forexample, the hydrogen consuming process and/or device 134 may beimplemented as an oven, an industrial oven (e.g., configured to meltsteel, glass, aluminum, etc.), an electric generator, a heating unit(e.g., used for residential and/or commercial heating), a stove, and thelike.

The foregoing described embodiments depict different componentscontained within, or connected with, different other components. It isto be understood that such depicted architectures are merely exemplary,and that in fact many other architectures can be implemented whichachieve the same functionality. In a conceptual sense, any arrangementof components to achieve the same functionality is effectively“associated” such that the desired functionality is achieved. Hence, anytwo components herein combined to achieve a particular functionality canbe seen as “associated with” each other such that the desiredfunctionality is achieved, irrespective of architectures or intermedialcomponents. Likewise, any two components so associated can also beviewed as being “operably connected,” or “operably coupled,” to eachother to achieve the desired functionality.

While particular embodiments of the present invention have been shownand described, it will be obvious to those skilled in the art that,based upon the teachings herein, changes and modifications may be madewithout departing from this invention and its broader aspects and,therefore, the appended claims are to encompass within their scope allsuch changes and modifications as are within the true spirit and scopeof this invention. Furthermore, it is to be understood that theinvention is solely defined by the appended claims. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to inventions containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations).

Conjunctive language, such as phrases of the form “at least one of A, B,and C,” or “at least one of A, B and C,” (i.e., the same phrase with orwithout the Oxford comma) unless specifically stated otherwise orotherwise clearly contradicted by context, is otherwise understood withthe context as used in general to present that an item, term, etc., maybe either A or B or C, any nonempty subset of the set of A and B and C,or any set not contradicted by context or otherwise excluded thatcontains at least one A, at least one B, or at least one C. Forinstance, in the illustrative example of a set having three members, theconjunctive phrases “at least one of A, B, and C” and “at least one ofA, B and C” refer to any of the following sets: {A}, {B}, {C}, {A, B},{A, C}, {B, C}, {A, B, C}, and, if not contradicted explicitly or bycontext, any set having {A}, {B}, and/or {C} as a subset (e.g., setswith multiple “A”). Thus, such conjunctive language is not generallyintended to imply that certain embodiments require at least one of A, atleast one of B, and at least one of C each to be present. Similarly,phrases such as “at least one of A, B, or C” and “at least one of A, Bor C” refer to the same as “at least one of A, B, and C” and “at leastone of A, B and C” refer to any of the following sets: {A}, {B}, {C},{A, B}, {A, C}, {B, C}, {A, B, C}, unless differing meaning isexplicitly stated or clear from context.

Accordingly, the invention is not limited except as by the appendedclaims.

1. A hydrogen generator for use with a water source and an electricalpower source, the hydrogen generator comprising: a plurality of plateseach having a plurality of through-holes formed therein, each of theplurality of plates being electrically conductive, the plurality ofplates comprising a first positive plate, a first negative plate, and afirst neutral plate, the first positive plate being configured to beconnected to a positive terminal of the electrical power source, thefirst negative plate being configured to be connected to a negativeterminal of the electrical power source, the plurality of plates beingarranged in a series with the first neutral plate being positionedbetween the first positive plate and the first negative plate,interstitial spaces being defined between adjacent ones of the pluralityof plates in the series; a plurality of seals each being positionedwithin a corresponding one of the interstitial spaces, each of theplurality of seals defining an interior shape that is closed along aperipheral portion of the seal within the corresponding interstitialspace and open along the adjacent plates defining the correspondinginterstitial space, the peripheral portion of each of the plurality ofseals being configured to position the plurality of through-holes formedin each of the adjacent plates defining the interstitial spacecorresponding to the seal in communication with the interior shapedefined by the seal to thereby form a sealed chamber that extendsthrough the series, each of the plurality of seals being electricallynon-conductive; a water inlet configured to allow water from the watersource into the sealed chamber, the water electrically connecting thefirst positive plate to the first negative plate, which causes the waterto split into oxygen and hydrogen; and a hydrogen outlet configured toallow the hydrogen to exit from the sealed chamber. 2.-12. (canceled)13. The hydrogen generator of claim 1, wherein the water comprises acatalyst.
 14. The hydrogen generator of claim 13, wherein the catalystis potassium hydroxide.
 15. (canceled)
 16. (canceled)
 17. A hydrogengenerator for use with a water source and an electrical power source,the hydrogen generator comprising: an electrolysis chamber having awater inlet and a hydrogen outlet, the water inlet being configured toreceive water from the water source, the hydrogen outlet beingconfigured to allow hydrogen generated inside the electrolysis chamberto exit therefrom; and a series of parallel plates positioned in theelectrolysis chamber and configured to generate the hydrogen, the seriesof parallel plates comprising at least one positive plate, at least onenegative plate, and at least one neutral plate, each of the series ofparallel plates comprising through-holes configured to allow the waterand the hydrogen to flow therethrough, the at least one positive platebeing configured to be connected to a positive terminal of theelectrical power source, the at least one negative plate beingconfigured to be connected to a negative terminal of the electricalpower source, the water inside the electrolysis chamber forming anelectrical connection between the at least one positive plate and the atleast one negative plate that splits the water into the hydrogen andoxygen.
 18. The hydrogen generator of claim 17, wherein the electrolysischamber is at least partially defined within a plurality of sealspositioned one each between each adjacent pair of plates within theseries of parallel plates.
 19. The hydrogen generator of claim 18,further comprising: first and second end caps flanking the series ofparallel plates; a first end cap seal positioned between the first endcap and the series of parallel plates; and a second end cap sealpositioned between the second end cap and the series of parallel plates,the electrolysis chamber extending from the first end cap to the secondend cap.
 20. The hydrogen generator of claim 19, wherein the water inletis formed in the first end cap, and the hydrogen outlet is formed in thesecond end cap.
 21. The hydrogen generator of claim 17, wherein the atleast one neutral plate comprises a plurality of neutral platesconfigured to provide a desired amount of electrical resistance betweenthe at least one positive plate and the at least one negative plate. 22.The hydrogen generator of claim 17, wherein the water comprises acatalyst.
 23. The hydrogen generator of claim 22, wherein the catalystis potassium hydroxide. 24.-26. (canceled)
 27. A hydrogen generator foruse with a water source and an electrical power source, the hydrogengenerator comprising: an electrolysis chamber divided into an oxygenchamber and a hydrogen chamber; at least one water inlet incommunication with the electrolysis chamber, each of the at least onewater inlet being configured to receive water from the water source; ahydrogen outlet in communication with the hydrogen chamber, the hydrogenoutlet being configured to allow hydrogen generated inside theelectrolysis chamber to exit therefrom; an oxygen outlet incommunication with the oxygen chamber, the oxygen outlet beingconfigured to allow oxygen generated inside the electrolysis chamber toexit therefrom; and a series of parallel plates positioned in theelectrolysis chamber and configured to generate the hydrogen, the seriesof parallel plates comprising at least one positive plate, at least onenegative plate, and at least one neutral plate, each of the series ofparallel plates comprising through-holes configured to allow the water,the oxygen, and the hydrogen to flow therethrough, the at least onepositive plate being configured to be connected to a positive terminalof the electrical power source, the at least one negative plate beingconfigured to be connected to a negative terminal of the electricalpower source, the water inside the electrolysis chamber forming anelectrical connection between the at least one positive plate and the atleast one negative plate that splits the water into the hydrogen and theoxygen.
 28. The hydrogen generator of claim 27, further comprising: aplurality of membranes each comprising through-holes configured to allowthe water, the oxygen, and the hydrogen to flow therethrough, each ofthe plurality of membranes being positioned at a different locationwithin the series of parallel plates; and a plurality of seals eachpositioned in between a different first one of the series of parallelplates and either a different second one of the series of parallelplates or a different one of the plurality of membranes, theelectrolysis chamber being at least partially defined within theplurality of seals, the plurality of seals dividing the electrolysischamber into the hydrogen chamber and the oxygen chamber.
 29. Thehydrogen generator of claim 28, further comprising: first and second endcaps flanking the series of parallel plates; a first end cap sealpositioned between the first end cap and the series of parallel plates;and a second end cap seal positioned between the second end cap and theseries of parallel plates, the electrolysis chamber extending from thefirst end cap to the second end cap.
 30. The hydrogen generator of claim29, wherein the each of the at least one water inlet is formed in thesecond end cap, the hydrogen outlet is formed in the second end cap, andthe oxygen outlet is formed in the second end cap.
 31. The hydrogengenerator of claim 29, wherein the at least one water inlet comprises afirst water inlet and a second water inlet, the first water inlet is incommunication with the hydrogen chamber, and the second water inlet isin communication with the oxygen chamber.
 32. The hydrogen generator ofclaim 27, wherein the at least one neutral plate comprises a pluralityof neutral plates configured to provide a desired amount of electricalresistance between the at least one positive plate and the at least onenegative plate.
 33. The hydrogen generator of claim 27, wherein thewater comprises a catalyst.
 34. The hydrogen generator of claim 33,wherein the catalyst is potassium hydroxide.